SiAION COMPOSITES AND METHOD OF PREPARING THE SAME

Abstract: A dense, substantially glass free, SiAION ceramic material and method of making such material. The material has at least an alpha-SiAION phase and a beta-SiAION phase and exhibits excellent high temperature oxidation resistance and strength, good room temperature toughness and hardness, and a density greater than at least 95 percent of theoretical density. The method of making the ceramic material is simple and includes adding AIN in an amount sufficient to allow formation of a desired amount of alpha-SiAION, and in addition, convert SiO2 and AI2O3 into the beta-SiAION phase, preferably, by adding AIN in an amount between 1.3X + .08Y - 0.0045XY and 1.3X + 0.2Y - 0.0024XY, wherein X is a weight percent of the SiO2 based on total weight of the Si3N4 in the mixture and Y is a weight percent of alpha-SiAION phase desired.

Description: SiAION COMPOSITES AND METHOD OF PREPARING THE SAME TECHNICAL FIELD This invention relates generally to SiAION composites and a method of preparing the same. More particularly, this invention relates to SiAION materials having no greater than 3 volume percent of intergranular amorphous phase and further having at least an alpha- SiAION phase and a beta-SiAION phase BACKGROUND AND SUMMARY OF INVENTION "SiAION"s are phases in silicon-alummum-oxygen-nitrogen and related systems, comparabie m variety and diversity with mineral aluminosiiicates They contain one-, two-, and three-dimensional arrangements of silicon oxide tetrahedra in which silicon and oxygen atoms are partially replaced by aluminum and nitrogen. See K. H. Jack, "Sialons and related nitrogen ceramics," 11 J. of Materials Sci. 1135-58 (1976). Ceramic materials made from SiAION typically have high toughness and elevated temperature strength and oxidation resistance. These properties have made SiAION ceramics a desirable candidate for many high temperature industrial applications In an attempt to provide a ceramic SiAION composition which is usable in high temperature applications, prior art methods and compositions have taught the combination of alpha-SiAION with beta-SiAION. Typically, alpha-SiAION, which appears mostly as fine equiaxed grains in the microstructure of the material, is associated with hardness in the material. On the other hand, beta-SiAION mostly appears as elongated fiber-like grains in the microstructure. See Hwang et al., U.S. Pat. No. 5,227,346. Since, the beta-SiAION material is elongated, it adds strength and fracture toughness to the material. Consequently, it is an advantage for a material made of SiAION to incorporate both alpha-phase and beta-phase SiAION. By varying starting materials in the SiAION composition, it is possible to vary the alpha- to beta-SiAION phase ratio. This will give rise to a series of materials where hardness and fracture toughness can be tailored. A common problem with multi-phase SiAION sintered bodies is that one or more minor phases, generally intergranular amorphous (glassy) phases, are formed at grain boundaries between the alpha- and beta-SiAION phases. These intergranular glasses are undesirable because they generally cause high temperature degradation and reduction of the overall strength of the ceramic material. The intergranular glasses also cause the bodies to have lower oxidation resistance, especially at high temperatures. This may lead to reduced mechanical reliability such as load-bearing capability of the sintered bodies. For a discussion of negative implications of oxidation in ceramics, see Tressler, "High-Temperature Stability of Non-Oxide Structural Ceramics", 18(9] MRS Bull. 58-63 (1993). For this reason, it would be advantageous to provide a multi-phase SiAION material with minimal or no intergranular glasses. Prior art compositions and methods have attempted to rid the SiAION materials of these glassy phases. For example, since oxide sintering additives contribute to the formation of glasses which remain at grain boundaries, attempts have been made to eliminate these additives from starting materials. However, these methods typically produce ceramic bodies that are difficult, if not impossible, to fully densify. Eliminating the additives from the starting materials also changes the microstructure of the resulting sintered bodies, inhibiting formation of elongated grains, and thus, impairing mechanical properties. Another method of removing the glasses from a ceramic body is a post-fire heat treatment. In this method, a densified ceramic body containing an intergranular amorphous o phase is exposed to temperatures between 1000°C and 1600°C in order to promote crystallization of the glassy phase. The crystallized phase provides better resistance to degradation at higher temperatures than the glass. However, a problem with post-fire heat treatment is that complete crystallization may be inhibited by kinetic factors such as a large volume change upon crystallization that causes stress in glass residues which are constrained by 5 surrounding grains. Even if complete crystallization occurs, the temperature at which strength degradation is observed is only raised to a temperature somewhere between the glass melting point (typically 900°C to 1000°C) to that of an eutectic temperature along the SiAION grain- boundaries (typically 1200°C to 1500°C). It would be desirable to have a method of forming a dense multi-phase SiAION 0 ceramic material having no greater than three volume percent of intergranular amorphous phase, but not having the above identified problems. In a first aspect, this invention is a SiAION ceramic material having no greater than 3 volume percent of intergranular amorphous phase consisting essentially of: (a) a first phase of alpha-SiAION represented by the general formula M x 5 (Si,AI)ι 2 (0,N)i6, wherein 0 < x .<.2 and M is at least one cationic element selected from the group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb; and (b) a second phase of beta-SiAION represented by the general formula Siβ-yAlyOy g-y, wherein 0 < y ^4.3. In a second aspect, this invention is a method for producing the SiAION ceramic 0 material of the first aspect. The method comprises subjecting a mixture of precursor materials to a pressure, temperature, and period of time sufficient to densify the mixture, wherein the precursor materials comprise Si 3 N , AIN, optionally Si0 2 , optionally Al 2 0 3 , and at least one oxygen or nitrogen derivative of an element selected from the group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb, and wherein Si0 2 , including surface oxide from Si 3 N 4 , is present in the mixture in an amount no greater than 5 weight percent of the total weight of the Si 3 N 4 , Al 2 0 3 , including surface oxide from AIN, is present in the mixture in an amount no greater than 6 weight percent based on total weight of the AIN, the Si 3 N is present in the mixture in a range from 70 to 95 weight percent based on total weight of the mixture, and the AIN is present in the mixture in a weight percent range, based on the total weight of the mixture, of from 1.3X + 0.08Y - 0.0045XY to 1.3X + 0.2Y - 0.0024XY, wherein X is the weight percent of the Si0 2 based on total weight of the Si 3 N and Y is from 1 to 90 and is equal to a weight percent of alpha-SiAION phase desired in the ceramic material. DETAILED DESCRIPTION Generally, this invention provides a dense, multi-phase SiAION ceramic material having no greater than three volume percent of intergranular amorphous phase and comprising a mixture of at least an alpha-SiAION phase and a beta-SiAION phase. The ceramic material exhibits excellent high temperature oxidation resistance and strength and has good room temperature toughness and hardness. ' The alpha-SiAION phase of this invention is represented by the general formula M x (Si,AI)i2 (0,N)i6- In this general formula, "M" is at least one cationic element selected from the group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb. "x" is a number greater than zero, but less than or equal to two. If the value of x exceeds 2, there will not be enough interstitial sites available in the lattice to accept the M cation, thus leading to formation of secondary phases and glass. Preferably, x is less than 1. Micrographs taken with a transmission electron microscope (TEM), or a scanning electron microscope (SEM), reveal that the alpha-SiAION phase is crystalline, containing mostly fine equiaxed grains along with a small amount of fine elongated grains, each grain having a diameter less than 0.5 micrometer (μm). In a preferred multi-phase SiAION ceramic material, M is a multicationic mixture of Sr, Ca, and Y. Another preferred embodiment is when M is a multicationic mixture of Mg, Ca, and Y. The beta-SiAION phase of this invention is represented by the general formula Si6-yAlyOy 8 . y , wherein 0 < y <_ 4.3. However, even within the above described range, if the value of y is too large, excessive grain growth may result. Excessive grain growth leads, in turn, to ormation of large pores in the resulting materials. The large pores typically lead to a reduction in the strength and oxidation resistance of the ceramic material. Therefore, the value of y should, preferably, be larger than 0 but not more than 2, most preferably, not more than 1. An SEM of the beta-SiAION phase of the preferred embodiment of this invention reveals large elongated grains having diameters greater than 0.3 μm, most preferably, greater than 0.5 μm. A significant part of this invention is the presence of no greater than three volume percent of intergranular amorphous phase (glassy phase) based on total volume of the SiAION ceramic material. Preferably, no greater than one volume percent of glassy phase is present. The glassy phase, when present, typically comprises Si, Al, O, N, and M, wherein M is the same cation, or mixture of cations, that are present in the alpha-SiAION phase. By eliminating or substantially reducing the glassy phase many beneficial properties such as excellent high temperature oxidation resistance and strength, as well as good room temperature toughness and hardness is obtained. The mechanical properties of the SiAION ceramic material are readily measured by use of standard tests. In particular, for purposes of this invention, the material is evaluated for oxidation resistance, Vicker's Hardness, Palmqvist Toughness, fracture toughness, flexure strength (modulus of rupture), and flexure strength retention. These standard tests are described in numerous previous publications. With the exception of oxidation resistance and flexure strength retention, these testing methods are specifically described in, for example, Hwang et al., U.S. Pat. No. 5,227,346, at col. 9, line 18 through col. 10, line 15. Flexure strength retention, which measures the percentage of flexure strength retained at elevated temperature versus that at room-temperature, is calculated by dividing elevated temperature (for example 1375°C) flexure strength by room temperature (about 23°C) flexure strength, and multiplying by 100. Oxidation measurements are reported as mass gain per unit area at a specified temperature and for a given amount of time. For example, in air oxidation of the material of this invention is no greater than 0.25 mg/cm 2 at 1400 c C for 100 hours and no greater than 1.00 mg/cm 2 at 1500°C for 50 hours. In contrast, SiAION compositions having greater than three volume percent of intergranular amorphous phase generally have significantly higher oxidation values. See, for example, Persson et al., "Oxidation Behaviour and Mechanical Properties of β- and Mixed α-β-Siaions Sintered with Additions of Y 2 0 3 and Nd 2 θ3," 11 J. Eur. Ceramic Soc. 363-73 (1993). The Vickers Hardness test measures the resistance of a ceramic material to indentation. The room temperature Vickers Hardness number of the SiAION ceramic material of this invention is at least 1650 kg/mm 2 . However, generally speaking, by increasing alpha- SiAION content (above 10 weight percent (wt-%)) and decreasing glass content (below 3 volume percent), high hardness values (above 1700 kg/mm 2 ) are easily obtainable with this invention. Preferably, the Vickers Hardness number ranges from 1650 kg/mm 2 to 2100 kg/mm 2 at room temperature; more preferably, from 1750 kg/mm 2 to 2000 kg/mm 2 . In addition, the flexure strength retention of the material is at least 55 percent at 1375°C in air. Preferably, the flexure strength retention is at least 65 percent at 1375°C in air. Room temperature fracture toughness, which measures the resistance of a material to fracture under a dynamic load, is greater than 4.0 MPa (m) 1 2 , as measured by the Chevron notch technique when the loading displacement rate is 1 μm/min. The room temperature fracture toughness generally ranges from 4.0 MPa (m) 1 2 to 7.5 MPa (m) 1 2 . Preferably, the room temperature fracture toughness is at least 5.0 MPa (m) 1 2 The SiAION bodies of this invention exhibit a room temperature Palmqvist toughness, which is an extension of the Vickers Hardness test, of at least 25 kg/mm. Preferably, the ceramic body of this invention exhibits a Palmqvist toughness at room temperature within a range of from 28 kg/mm to 45 kg/mm; more preferably, from 32 kg/mm to 40 kg/mm. The alpha- and beta-SiAION phases may be present in any amount as long as both phases are present in the ceramic material. Physical properties of the SiAION composites can be altered by changing the ratio of the alpha and beta-SiAION phases. For example, by increasing the percentage of alpha-phase, hardness of the material increases and toughness of the material decreases. Generally, a weight ratio of alpha- to beta-SiAION, measured by a peak height ratio from X-ray diffraction (XRD) patterns, is anywhere from 1 :99 to 90: 10. Below 1 :99, the material is typically more difficult to densify and above 90: 10 strength and toughness diminish. Preferably, the weight ratio is between 10:90 and 40:60. Preferably, the SiAION ceramic material of this invention is substantially fully dense, having no significant porosity and a density of greater than 95 percent of the theoretical value. More preferably, the density is greater than 97 percent of the theoretical value; and most preferably, greater than 99 percent of the theoretical value. The SiAION ceramic materials of this invention are prepared by densifying a powder mixture of precursor materials. The precursor materials include Si 3 N 4 , AIN, optionally Si0 2 , optionally Al 2 0 3 , and at least one oxygen or nitrogen derivative of an element selected from the group consisting of Sr, Ca, Mg, Li, Na, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb. The Si 3 N precursor material used in preparing the ceramic material of this invention is present in an amount which is suitably within a range of from 70 to 95 wt-% based on total weight of the mixture. The Si 3 N can be any Si 3 N powder, including the crystalline forms of alpha-Si 3 N and beta-Si 3 N 4 , or noncrystalline amorphous Si 3 N , or mixtures thereof. However, the preferred form of Si 3 N 4 powder has a high purity and a high alpha/beta weight ratio, in addition, the powder may be of any size or surface area provided the ceramic material of this invention is obtained. Preferably, the particles have an average diameter within a range of from 0.2 μm to 5.0 μm; more preferably, from 0.2 μm to 1.0 μm. The powder has a surface area that is desirably within a range of from 5 m 2 /g to 15 m 2 /g, as determined by the Brunauer- Emmett-Teller (BET) method of measuring surface area, which is described in C. N. Satterfield, Heterogeneous Catalysis in Practice 102-05 (McGraw-Hill Book Company, 1980). The range is preferably from 8 m /g to 12 m 2 /g. Oxygen is inherently introduced into the mixture, usually as oxide or oxynitride coatings on surfaces of starting powders such as Si 3 N and AIN particles. Although it may be possible for the oxygen to be present in other forms, it is generally believed to exist predominantly in the form of Si0 2 and Si-O-N on the Si 3 N and Al 2 0 3 and Al-O-N on the AIN. For calculation purposes, one skilled in the art will be able to convert any oxygen content to an equivalent content of Si0 2 and Al 2 0 3 . Thus, for purposes of this invention, the oxygen content of the mixture is identified in terms of wt-% of Si0 2 and Al 2 0 3 . The amount of Sι0 2 and Al 2 0 3 introduced inherently from the S13N4 and AIN particles varies according to the purity of the starting powders and their methods of manufacture Typically, the amount of Sι0 2 , introduced naturally through the Sι 3 N 4 powder, ranges from 1 5 to 5 0 wt-% , based on the total weight of the S13N4 Thus, for purposes of this invention, any given wt-% of S13N4 or AIN inherently includes its respective wt-% of oxide Additional amounts of Sι0 2 may also be directly added to the mixture, but preferably, for purposes of this invention, the total amount of Sι0 2 introduced into the mixture (inherently and directly) is no greater than 5 wt-% of the total weight of the S13N4 The amount of Al 2 0 3 introduced naturally through the AIN powder typically ranges from 1 5 to 6 0 wt-%, based on the total weight of the AIN Additional amounts of Al 2 0 3 may also be directly added to the mixture, but preferably, for purposes of this invention, the total amount of Al 2 0 3 introduced into the mixture (inherently and directly) is no greater than 6 O wt-% of the total weight of the AIN ' At least one oxygen or nitrogen derivative of an element selected from the metal group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb is added to the mixture The "oxygen or nitrogen derivative" includes any compound of oxygen, nitrogen, or both oxygen and nitrogen, wherein the compound has at least one element from the above identified metal group The oxygen or nitrogen derivative may be added in any amount provided the SiAION ceramic material of this invention is formed Preferably, the oxygen or nitrogen derivative is added in an amount between 0 1 wt-% and 20 0 wt-% based on total weight of the mixture, wherein the wt-% is calculated as that of the oxide form of the derivative One skilled in the art will be able to convert a wt-% of any oxygen or nitrogen derivative (for example CaCθ3> to the equivalent wt-% in its oxide form (for example CaO) More preferably, the oxygen or nitrogen derivative is added in an amount between 0 5 wt-% and 10 wt-% based on total weight of the mixture To obtain SiAION ceramic materials having no greater than three volume percent glassy phase as measured from SEM and TEM photomicrographs, AIN must be introduced in an amount sufficient to allow formation of a desired amount of alpha-SiAION, and in addition, sufficient to convert the oxides (Sι0 2 and AI2O3) into the beta-SiAION phase AIN is responsible, in one role, for reacting with the Si3N and the oxygen or nitrogen derιvatιve(s) to form the alpha-SiAION phase In another role, in order to prevent or minimize formation of intergranular amorphous phases, an additional amount of AIN is required in order to react with the Sι0 2 , AI 2 θ3, and Sι 3 N 4 to form beta-SiAION Adding additional Sι 3 N is not necessary to form the beta-SiAION in this invention since the amount of S13N4 added (from 70 to 95 wt-%) will be sufficient to form both alpha- and beta-SiAION phases The amount of AIN added must, however, be less than an amount necessary to form AIN polytypoids For a discussion of AIN polytypoids, see Cannard et al , "The Formation of Phases in the AIN-πch Corner of the Si-AI-O-N System," 8 J Eur Ceramic Soc 375-82 (1991 ), and Bergman, "The Si-AI-O-N System at Temperatures of 1700-1775°C", BJ Eur Ceramic Soc 141-51 (1991 ) Formation of AIN polytypoids can adversely affect mechanical properties of the SiAION material by lowering both the melting point and the oxidation resistance The existence of AIN polytypoids may be measured by such methods as XRD analysis For purposes of this invention, it is possible that an amount of AIN polytypoids that is below the detection limit of typical XRD analysis (less than 2 wt-%) may form without adversely affecting the material Thus, addition of an amount of AIN that forms less than the XRD analysis AIN polytypoid detection limit is considered within the scope of this invention and " less than an amount necessary to form AIN polytypoids " Preferably, the amount of AIN in wt-% is between 1 3X + 08Y - 0 0045XY and 1 3X + 0 2Y - 0 0024XY, wherein "X" is the wt-% of the Sι0 2 based on total weight of the Sι 3 N 4 and "Y" is a wt-% of alpha-SiAION phase desired in the ceramic material As discussed previously, one skilled in the art may also convert the wt-% of Sι0 2 to an equivalent oxygen content For example, if "X"' is equal to oxygen content (instead of Sι0 2 content) based on total weight of the Sι 3 N 4 , the amount of AIN is between 2 4X' + 08Y - 0 008XΥ and 2 4X' + 0 2Y - 0 004XΥ, wherein " Y" is the wt-% of alpha-SiAION phase desired in the ceramic material Generally, if a molar ratio of total Sι0 2 to total AI2O3 is at least 25 to 1 , the desirable amount of AIN is closer to a lower limit of 1 3X + 08Y - 0 0045XY In contrast, the desirable amount of AIN is closer to an upper limit of 1 3X + 0 2Y - 0 0024XY if a molar ratio of total Sι0 2 to total Al 2 0 3 is less than 25 to 1 As discussed previously, a preferred multi-phase SiAION ceramic material comprises an alpha-SiAION phase expressed by the chemical formula M x (Sι,AI) 12 (0,N) l6 , where 0 < x <_ 2, and M is a multicationic mixture of Sr, Ca, and Y This ceramic material preferably has an alpha :beta-SιAION phase wt-% ratio of 20:80 A preferred method for forming this ceramic material is, first, to form a precursor mixture containing 92 7 wt-% S13N4 having 2.3 wt- % Sι0 2 based on total weight of the S13N4, 5 5 wt-% AIN having 2 1 wt-% AI2O3 based on the total weight of the AIN, 0 5 wt-% SrO, 0 3 wt-% CaO, and 1 0 t-% Y 2 0 3 , all wt-%'s, unless otherwise indicated, being based on the total weight of the precursor mixture This mixture may then be densif led by the method of this invention (discussed infra) The desirable preparation of a finely-divided powder mixture containing the precursor materials may be accomplished in any suitable manner with conventional apparatus A preferred method of preparing the precursor mixture includes attrition milling, with attπtor media, preferably zirconia balls, in a carrier medium (or solvent) for a period of time sufficient to form a finely-dispersed suspension The preparation of the finely-dispersed suspension requires no particular order of addition of the precursor materials to the carrier medium After attrition milling, excess carrier medium is removed by filtration or otherwise The mixture is then dried and separated from the attπtor media to yield a product having substantially the same proportions as the original ingredients The carrier medium may be any inorganic or organic compound which is a liquid at room temperature and atmospheric pressure Examples of suitable carrier media include- water; alcohols, such as methanol, ethanol and isopropanol; ketones, such as acetone and methyl ethyl ketone; aliphatic hydrocarbons, such as pentanes and hexanes; and aromatic hydrocarbons, such as benzene and toluene. The carrier medium is desirably aqueous. The function of the carrier medium is to impart a viscosity suitable for mixing the solid powders Any quantity of carrier medium which achieves this purpose is sufficient and acceptable. Preferably, a quantity of carrier medium is employed such that the solids content is in a range from 15 volume percent to 50 volume percent based on a total volume of the suspension. Below the preferred lower limit, the viscosity of the solid suspension may be too low and deagglomeration mixing may be ineffective Above the preferred upper limit, the viscosity may be too high, and deagglomeration mixing may be difficult If the carrier medium is toluene, a coupling agent, such as an aluminate coupling agent commercially available from Kenπch Petrochemicals under the trade designation KEN- REACT KA 322, may be used to aid in forming a suspension When using an alcohol such as methanol, a dispersant such as a polyethyieneimine may be used to facilitate mixing and a f loccuiant such as oleic acid may be used to ease recovery of the powder mixture. When using water, an ammo-alcohol dispersant such as AMP98 from Angus Chemical Co. may be used to facilitate mixing. To limit the tendency of active nitrides (for example AIN) to hydroiyze in the presence of moisture, the active nitrides are generally not added into the mixture until the last approximately 15 minutes of milling. To aid in the dispersion of components of the powder mixture, one or more surfactants or dispersants can be added to the suspension. The choice of surfactant(s) or dispersant(s) can vary widely as is well-known in the art. Any amount of sur actant or dispersant is acceptable provided dispersion of powder mixture components is improved. Typically, the amount of surfactant is in a range of from 0.01 to 2.0 wt-% of the powder mixture. The components of the powdered combination are added to the carrier medium in any manner which gives rise to a finely dispersed suspension of the components. Typically, the process is conducted in a large vessel at room temperature under air with vigorous stirring Any common mixing means is suitable, such as a ball-milling device or an attrition mixer. An ultrasonic vibrator may be used in a supplementary manner to break down smaller agglomerates. The attrition mixer is preferred. Once mixed, the finely-dispersed suspension is ready for processing into greenware for eventual sintering. For example, the suspension can be slip-cast by techniques well-known in the art Alternatively, the suspension can be dried into a powder and ground for use in a hot-pressing process as is well-known in the art. A typical process is disclosed in Pyzik, U.S. Pat. No. 5,120,328, col. 9, lines 31-65. Drying may be accomplished by standard drying means, such as by spray-drying or oven drying. Preferably, drying of the admixture of the powder mixture and the attritor balls is accomplished in an oven under a nitrogen purge after removal of excess carrier medium. During the drying process, additional free carrier medium is removed. The temperature of the drying depends on the boiling point of the carrier medium employed. Typically, the drying process is conducted at a temperature just below the boiling point of the carrier medium under atmospheric pressure. After drying, the resulting powder is separated from the attritor media or balls and sieved through a screen to obtain a powder 0 which then may be densified. Any method of densifying the powder will suffice provided the ceramic material of this invention is formed. The preferred method of densifying the powder mixture is by either hot-pressing, hot isostatic pressing (HIP), or gas pressure sintering, each of which is a well known method of densif ication in the art. Most preferably, the method is hot-pressing, which 5 comprises heating the powder under pressure to obtain the densified ceramic body. Any standard hot-pressing equipment is acceptable, such as a graphite die equipped with a heating means and a hydraulic press. Particularly suitable results are obtained when the die is fabricated from a material which is substantially non-reactive with components of the powder mixture at hot-pressing temperatures and has a mean linear coefficient of expansion greater 0 than that of the SiAION. Hot-pressing may be conducted under an inert atmosphere, such as nitrogen, to prevent oxidation and decomposition of the Si 3 N at high temperatures. The direction of pressing is uniaxial and perpendicular to the plane of the die plates. Any processing temperature and pressure will suffice providing the novel SiAION ceramic material of this invention, described herein, is obtained. Typically, however, the 5 temperature for hot-pressing is between 1550"C and 1950°C. Preferably, the temperature is maintained within a range of from 1750°C to 1950°C during pressurizing. More preferably, the range is from 1825°C to 1925°C. At these temperatures for hot-pressing, a pressure of between 20 MPa and 40 MPa is typically applied in order to attain substantially full densif ication. It is noted that the accurate measurement of high temperatures, such as those 30 quoted hereinabove, is technically difficult. Some variation in the preferred temperature range may be observed depending on the method employed in measuring the temperature. The preferred temperatures of this invention are measured by a tungsten-rhenium thermocouple, obtained from and calibrated by the Omega Company. Generally, when densifying the mixture by HIP, a pressure of between 10 MPa and 35 200 MPa is applied at a temperature of between 1550°C to 2100°C. However, when densifying the mixture by gas pressure sintering a typical pressure of between 1 MPa and 10 MPa is applied at a temperature of between 1650°C to 2050°C. The amount of time that the powder mixture is heated under pressure should be sufficient to bring the powder to essentially complete densif ication Those skilled in the art will be able to determine suitable times without undue experimentation For example, ram movement during hot-pressing is a good indicator of the extent of densif ication As long as the ram continues to move, densif ication is incomplete When the ram has stopped moving for at least 15 minutes, the densif ication is essentially complete at at least 95 percent or greater of the theoretical value. Preferably, the density of the material is greater than 97 percent of the theoretical value when ram movement stops. Most preferably, the density of the material is greater than 99 percent of the theoretical value when ram movement stops Thus, the time required for hot- pressing is the time during ram movement plus an additional 15 to 30 minutes Preferably, the time is within a range of from 15 minutes to 5 hours; more preferably, from 30 minutes to 90 minutes; and most preferably, 45 minutes to 75 minutes The methods of densif ication, described hereinbefore, allow for the formation of SiAION ceramic articles which can be used for such applications as cutting tools and engine components, particularly high wear and high temperature components A variety of shapes can be made; one common shape being a flat plate Articles such as cutting tools can be fabricated by slicing and grinding these plates into a variety of appropriate shapes EXAMPLES The following examples serve to illustrate the novel, dense, SiAION ceramic materials of this invention and the method of preparing said materials The examples are not intended to limit the scope of this invention. The Si 3 N 4 powder was commercially available from Ube Industries, Ltd. under the trade designation SN-E 10. It contained: 1.2 wt-% oxygen; less than 100 ppm Cl; less than 100 ppm Fe; less than 50 ppm Ca; and less than 50 ppm Al. It had a crystallinity of greater than 99.5 percent, a ratio of β/(α+β) of less than 5, and a surface area of 11.2 m /g. Tokuyama Soda Kabushiki Kaisha supplied AIN powder which had 0.9 wt-% oxygen. Moiy Corp. supplied Y 2 0 3 , and Alfa Products supplied MgO, SrO, AI2O3, and Si0 2 Aldnch Chemical Co. supplied CaO. Zirconia, in the form of zirconia balls, was available from Union Process. EXAMPLE 1 A series of precursor mixtures was prepared using the components and wt-% amounts identified as Mixtures (A)-(D) in Table I, infra. Each mixture was formulated to produce a SiAION ceramic material having a nominal 20 wt-% alpha phase "Nominal" alpha- SiAION content refers to a calculated alpha-SiAION content in a theoretical precursor mixture wherein no surface oxides exist in the mixture. Mixture A was not formulated to compensate for any Si0 2 and AI 2 O3; Mixture B was formulated to compensate for half of the Si0 2 and AI2O3; and Mixtures C and D were formulated, under the method of this invention, to compensate for all of the Si0 2 and AI2O3 The precursor mixtures were formed into greenware by, first, attrition milling each mixture separately in an attritor (Union Process batch attritor, Model 01 HD - 750 cc capacity with polytetraf luoroethylene coated tube and stirrer) containing zirconia balls and a carrier medium with a stirring rate of 300 revolutions per minute (rpm) and for a mixing time of 1 hour to form a slurry Methanol was used as the carrier medium in an amount sufficient to provide a solids content of 15 to 30 volume percent solids The slurry was poured through a 400 mesh (37 μm) plastic sieve to remove the zirconia balls, then dried in a 65°C oven Finally, the dried powder was sieved through 60 mesh (180 μm) screen to form a finely-divided powder mixture Table I About 85 grams of each powder mixture was densified by either hot pressing or HIP as discussed supra, and specifically identified in Tables ll-V, to form billets having an approximate size of 1.27cm X 3 81 cm X 5 08 cm for samples that were hot-pressed and 1.5cm X 2.0cm X 5 8cm for samples that were densified by HIP These samples are identified in the tables as Sample Numbers 1-17 Table II identifies Mixtures (A)-(C) which were hot pressed under flowing nitrogen at a pressure of 35 MPa Sample Numbers 1-3 in Table II were hot pressed for 1 hour at 1825°C and Sample Numbers 4-5 were hot pressed an additional 5 hours at 1925°C Tables lll-V identify Mixtures (A)-(D) which were densified by HIP under the following varying conditions: Table III mixtures were densified by HIP for 1 hour at 1825°C; Table IV mixtures' had an increased amount of time at HIP of 2 hours at the same temperature; and Table V mixtures were densified for 1 hour, but the temperature of the HIP was increased to 1925°C Each of Tables ll-V report various properties for each Sample Number The density of each Sample Number was measured by the water immersion method, as described in Richerson et al., Modern Ceramic Engineering (1982), and the volume percent (v/o) of intergranular amorphous phase ("glass content") was measured by SEM and TEM photomicrographs Vicker's hardness, Palmqvist Toughness, fracture toughness, room temperature strength, flexure strength, flexure strength retention, and oxidation resistance were also measured Results of each table are briefly discussed below each respective table Table II Prepared By Hot Press Table II (continued) Prepared By Hot Press This Sample is not an embod ment o the nvent on. Sample Numbers 1 , 2, and 4 had too much glass ( >3 v/o) and had less oxidation resistance and strength retention than Sample Number 5, which was prepared from a precursor material mixture formulated and processed in accordance with the present invention. Sample Number 3 was the same precursor material mixture as Sample Number 5, having a glass content less than 1 volume percent, but the density was low (77.5%). Increasing the temperature and time at hot press on Sample Number 3 produced Sample Number 5, a substantially fully dense (99.6%) material which still had a glass content less than 1 volume percent. Table III Prepared By HIP This Sample is not an embo iment o the invent on. Sample Numbers 6 & 7 had too much glass (>3 v/o) and had less oxidation resistance and strength retention than Sample Numbers 8 & 9, which had been prepared from precursor material mixtures formulated and processed in accordance with the present invention. Table IV Prepared by HIP Materials 10 & 11 had too much glass (>3 v/o) and had less oxidation resistance and strength retention than Sample Numbers 12 & 13, which had been prepared from precursor material mixtures formulated and processed in accordance with the present invention. uι l in σ Nl Nl in o Table V Prepared By HIP This Sample is not an embod ment o the invention. Materials 14 & 15 had too much glass (>3 v/o) and had less oxidation resistance than Sample Numbers 16 & 17, which had been prepared from precursor material mixtures formulated and processed in accordance with the present invention. EXAMPLE 2 A series of precursor mixtures was prepared using the methods described in Example 1 , with the exception that each mixture was formulated to have a different alpha- SiAION content. These mixtures are identified as Mixtures (E)-(H) in Table VI, infra. Mixtures F and H were formulated, under the method of this invention, to compensate for the Siθ2 and Al 2 0 3 . TABLE VI Mixtures (E)-(H) were each hot pressed under flowing nitrogen at 35 MPa under conditions set out in Table VII to form billets of approximate size 1.27cm X 3.81cm X 5.08 cm, identified as Sample Numbers 18-21. In this table "nominal" alpha-SiAION content refers to the alpha-SiAION content present in a theoretical composition wherein no surface oxides exist in starting materials. "Measured" refers to actual alpha-SiAION content which was present in the composition as measured by XRD. Table VII reports various properties for each Sample Number. Results of the table are brie ly discussed below the table. Ul Ul M Nl in o in o TABLE VII Prepared By Hot Press ) ro This Sample is not an embodiment of the invention. By adjusting the amount of AIN to compensate for surface oxides (calculated as Si0 2 and AI2O3) by the method of this invention in Sample Numbers 19 and 21 , the amount of glass was less than in Sample Numbers 18 and 20, and the actual alpha-SiAION content was close to the nominal alpha-SiAION content. One may also note that Sample Number 19 had been densified under hot press conditions for an additional one hour at 1925°C. However, as demonstrated in Table II, additional time and temperature at hot press conditions had minimal effect on glass content in the materials of this invention, but was advantageous for increasing the density. EXAMPLE 3 A series of precursor mixtures was prepared using the methods described in Example 2. These mixtures are identified as Mixtures (l)-(L) in Table VIII, infra. Mixtures J and L were formulated, under the method of this invention, to compensate for the Siθ2 and Al 2 0 3 . TABLE VI I I Mixtures (l)-(L) were each hot pressed under flowing nitrogen at 35 MPa under conditions set out in Table IX to form billets of approximate size 1.27cm X 3.81cm X 5.08 cm, identified as Sample Numbers 22-25. Table IX reports various properties for each Sample Number. Results of the table are briefly discussed below the table. TABLE IX Prepared By Hot Press l This example demonstrates that the invention is also applicable to both multi- cation (Y-Mg-Ca)-SiAION and single-cation (for example, Y-SiAION) systems. Sample Numbers 23 and 25, formulated under the method of this invention, both had glass contents less than 1 volume percent. Therefore, from the results of Examples 1-3, as shown in Tables l-IX, it can be seen that the invention provides a ceramic material which exhibits excellent oxidation resistance and strength retention at elevated temperatures, and good room temperature toughness and hardness. The present material may have these superior properties due to the reduction of intergranular amorphous phase in SiAION having both alpha- and beta-SiAION phases. This reduction of glassy phase seems to yield a material which has superior properties over prior art materials. While the invention has been described in terms of specific embodiments, it will be appreciated that other embodiments could readily be adapted by one skilled in the art. Accordingly, the scope of the invention is to be limited only by the following claims.

Claims: CLAIMS I . A SiAION ceramic material having no greater than 3 volume percent of intergranular amorphous phase consisting essentially of: (a) a first phase of alpha-SiAION represented by the general formula M x (Si,AI)ι 2 (O.N β, wherein 0 < x <_ 2 and M is at least one cationic element selected from the group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb; and (b) a second phase of beta-SiAION represented by the general formula Si6.yAi y O y N 8 .y, wherein 0 < y <.4.3. 2. The ceramic material of Claim 1, wherein 0 < y < 1. 3. The ceramic material of Claim 1 , wherein the volume percent of intergranular amorphous phase is no greater than 1 volume percent. 4. The ceramic material of Claim 1 , wherein oxidation of the material is no greater than 0.25 mg/cm at 1400°Cfor 100 hours. 5. The ceramic material of Claim 1, wherein the oxidation of the material is no greater than 1.00 mg/cm 2 at 1500°C for 50 hours. 6. The ceramic material of Claim 1 , wherein density of the material is greater than 95 percent of the theoretical value. 7. The ceramic material of Claim 1 , wherein the alpha-SiAION and beta- SiAION are present in an alpha: beta weight ratio that is from 1 :99 to 90: 10. 8. The ceramic material of Claim 1 , wherein the alpha-SiAION and beta- SiAION are present in an alpha: beta weight ratio that is from 10:90 to 40:60. 9. The ceramic material of Claim 1 , wherein M is a multicationic mixture of Sr, Ca, and Y or a multicationic mixture of Mg, Ca, and Y. 10. The ceramic material of Claim 1 , wherein the flexure strength retention of the material is at least 55 percent at 1375°C in air. I I. A method of producing a SiAION ceramic material having no greater than 3 I volume percent of intergranular amorphous phase and consisting essentially of an alpha- SiAION phase and a beta-SiAION phase, the method comprising subjecting a mixture of precursor materials to a pressure, temperature, and period of time sufficient to densify the mixture, wherein the precursor materials comprise S13N 4 , AIN, optionally Si0 2 , optionally AI 2 O3, and at least one oxygen or nitrogen derivative of an element selected from the group consisting of Li, Na, Mg, Ca, Sr, Ce, Y, Nd, Sm, Gd, Dy, Er, and Yb, and wherein Si0 2 , including surface oxide from S13N4, is present in the mixture in an amount no greater than 5 weight percent of the total weight of the Si 3 N , AI2O 3 , including surface oxide from AIN, is present in the mixture in an amount no greater than 6 weight percent based on total weight of the AIN, the Si3N is present in the mixture in a range from 70 to 95 weight percent based on total weight of the mixture, and the AIN is present in the mixture in a weight percent range, based on the total weight of the mixture, of from 1.3X -I- 0.08Y - 0.0045XY to 1.3X + 0.2Y - 0.0024XY, wherein X is the weight percent of the Si0 2 based on total weight of the Si 3 N 4 and Y is from 1 to 90 and is equal to a weight percent of alpha-SiAION phase desired in the ceramic material. 12. The method of Claim 11, further comprising a step of attrition milling the mixture with attritor media in carrier medium, followed by drying and separating the mixture from the attritor media before densification. 13. The method of Claim 11 wherein the densifying is by hot pressing the mixture at a pressure of between 20 MPa and 40 MPa, a temperature of between 1550°C to 1950°C, and for a period of time between 1 to 5 hours. 14. The method of Claim 11 wherein the densifying is by hot isostatic pressing the mixture at a pressure of between 10 MPa and 200 MPa, a temperature of between 1500°C to 2100°C, and for a period of time of 1 hour. 15. The method of Claim 11 wherein the densifying is by gas pressure sintering the mixture at a pressure of between 1 MPa and 10 MPa, a temperature of between 1650°C to 2050°C, and for a period of time between 1 to 6 hours. 16. The method of Claim 11 , wherein the oxygen or nitrogen derivative is present in an amount between 0.1 and 20.0 percent by weight based on total weight of the mixture. 17. The method of Claim 11, wherein the oxygen or nitrogen derivative is present in an amount between 0.5 and 10.0 percent by weight based on total weight of the mixture. 18. The method of Claim 11 , wherein the oxygen or nitrogen derivative is formed from yttrium, strontium, and calcium, the amount of AIN is between 5.5 and 6.9 percent by weight of the total mixture, X is 2.1 , and Y is 20. 19. The method of Claim 18, wherein the oxygen or nitrogen derivative is formed from yttrium, magnesium, and calcium, the amount of AIN is between 5.3 and 6.7 percent by weight of the total mixture, X is 2.1 , and Y is 20.

Inventors: BEAMAN DONALD R, HWANG CHINMAU JAMES, SUSNITZKY DAVID W, BEAMAN, DONALD, R., HWANG, CHINMAU, JAMES, SUSNITZKY, DAVID, W.
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1994
Main classification: C04B35
IPC codes: C04B35